Synthetic fiber having high neutralized alkyl phosphate ester finish level

Abstract

A two-component staple fiber finish is disclosed which renders polyester staple fiber having low to normal modulus and tenacity-at-break fit for "100%" open end spinning. A synthetic fiber having from about 0.08 to about 0.15 weight percent, based on the total weight of the fiber, of a primary finish comprising (a) from 25 to 85 weight percent of at least one alkyl phosphate ester salt, and (b) from 15 to 75 weight percent of a second component selected from the group consisting of quaternary trialkyl ethyl ammonium ethosulfate salts and the reaction products of polyoxyethylene ethers and C 8 -C 22 fatty acids is claimed. The use of a secondary lubricant to enhance the carding and drawing characteristics of the staple fiber is also disclosed.

We claim: 
     
       1. A synthetic staple fiber, adapted for open end spinning having a finish thereon comprising: (a) from about 0.08 to about 0.15 percent of a primary finish comprising (i) from 25 to 85 weight percent of at least one alkyl phosphate ester salt; and   (ii) from 15 to 75 weight percent of a second component selected from the group consisting of quaternary trialkyl ethyl ammonium ethosulfate salts and the reaction products of polyoxyethylene ethers and C 8  -C 22  fatty acids, and     (b) from 0.01 to 0.06 weight percent of a secondary lubricant, with the proviso that said staple fibers possess an "ends down"/1000 spindle hours of open end spinning at a rotor speed of 50,000 rpm of 100 or less.     
     
     
       2. The synthetic staple fiber of claim 1 wherein said secondary lubricant comprises a 70/30 weight percent mixture of butyl stearate and an ethoxylated sorbitol ether capped with six moles of oleic acid. 
     
     
       3. The synthetic staple fiber of claim 1 wherein said secondary lubricant comprises a 69/23/8 weight percent mixture of a 50/50 blend of polyoxyethylene ethers capped with oleic acid and pelargonic acid, a blend of n-octyl adipate and n-decyl adipate, and soya dimethyl ethyl ammonium ethosulfate. 
     
     
       4. The synthetic staple fiber of claim 1 wherein said secondary lubricant comprises a 30.5/30.5/29/10 weight percent mixture of a 50/50 blend of polyoxyethylene ethers capped with oleic acid and pelargonic acid, a blend of n-octyl adipate and n-decyl adipate, a polyoxyethylene ether capped with oleic acid on one end and methyl on the other, and soya dimethyl ethyl ammonium ethosulfate. 
     
     
       5. The synthetic staple fiber of claim 1 wherein said secondary lubricant comprises a 50/20/5/20 weight percent mixture of mineral oil, a blend of polyoxyethylene ethers capped on one end with a blend of C 12  -C 18  alkanols, oleic acid, and a 50/50 blend of polyoxyethylene ethers capped with oleic acid and pelargonic acid. 
     
     
       6. A polyester staple fiber, adapted for open end spinning, having a tenacity-at-break of from 3.0 to 7.0 grams-force/denier and a modulus of from 12 to 50 grams-force/denier additionally having a finish thereon comprising: (a) from about 0.08 to about 0.15 percent percent of a primary finish comprising (i) from 25 to 85 weight percent of at least one alkyl phosphate ester salt; and   (ii) from 25 to 85 weight percent of second component selected from the group consisting of quaternary trialkyl ethyl ammonium ethosulfate salts and the reaction products of polyoxyethylene ethers and C 8  -C 22  fatty acids,     (b) from 0.01 to 0.06 weight percent of a secondary lubricant, with the proviso that said staple fiber possess an "ends down"/1000 spindle hours of open end spinning at a rotor speed of 50,000 rpm of 100 or less.     
     
     
       7. The polyester staple fiber of claim 6 wherein said tenacity-at-break ranges from 3.0 to 5.0 gram-force/denier and said "ends down"/1000 hours of open end spinning is 50 or less. 
     
     
       8. The polyester staple fiber of claim 7 wherein said secondary lubricant comprises a 70/30 weight percent mixture of butyl stearate and an ethoxylated sorbitol ether capped with six moles of oleic acid. 
     
     
       9. The polyester staple fiber of claim 7 wherein said secondary lubricant comprises a 69/23/8 weight percent mixture of a 50/50 blend of polyoxyethylene ethers capped with oleic acid and pelargonic acid, a blend of n-octyl adipate and n-decyl adipate, and soya dimethyl ethyl ammonium ethosulfate. 
     
     
       10. The polyester staple fiber of claim 7 wherein said secondary lubricant comprises a 30.5/30.5/29/10 weight percent mixture of a 50/50 blend of polyoxyethylene ethers capped with oleic acid and pelargonic acid, a blend of n-octyl adipate and n-decyl adipate, a polyoxyethylene ether capped with oleic acid on one end and methyl on the other, and soya dimethyl ethyl ammonium ethosulfate. 
     
     
       11. The polyester staple fiber of claim 7 wherein said secondary lubricant comprises a 50/20/5/20 weight percent mixture of mineral oil, a blend of polyoxyethylene ethers capped on one end with C 12  -C 18  alkanols, oleic acid, and a 50/50 blend of polyoxyethylene ethers capped with oleic acid and pelargonic acid. 
     
     
       12. A polyester staple fiber, adapted for open end spinning, having a tenacity-at-break of from 3.0 to 7.0 grams-force/denier and a modulus of from 12 to 50 grams-force/denier additionally having a finish thereon comprising: (a) from about 0.08 to about 0.15 percent of a primary finish consisting essentially of (i) from 25 to 85 weight percent of at least one alkyl phosphate ester salt; and   (ii) from 25 to 85 weight percent of second component selected from the group consisting of quaternary trialkyl ethyl ammonium ethosulfate salts and the reaction products of polyoxyethylene ethers and C 8  -C 22  fatty acids,     (b) from 0.01 to 0.06 weight percent of a secondary lubricant, with the proviso that said staple fiber possess and "ends down"/1000 spindle hours of open end spinning at a rotor speed of 50,000 rpm of 100 or less.